ROADCARE (M) SDN BHD

COLD IN-PLACE RECYCLING

TECHNOLOGY
By:
Muhamad Radzif

Cold In-place Recycling (CIPR)
COLD IN-PLACE RECYCLING
(CIPR)

In this technique, the recycling machine scarifies
the existing pavement layers, to maximum depth of
350mm, then adds either cement or bituminous
materials or both as stabilizing additives before
relaying it back on the same pavement area in a
single process. CIPR provides a more cost-
effective alternative to pavement rehabilitation that
requires partial or total reconstruction .
BACKGROUND OF CIPR
Pavement Recycling has been used in Malaysia since 28
years ago
1985 - Rehabilitation of FT02 between Kuala Lumpur and
Kuantan (Temerloh)
1988 - FT 08 between Pagar Sasak and Merapoh, Pahang
using cement as a stabilising agent
2002 Jalan Felda Bukit Sagu in Pahang (Foamed bitumen)
Until now more than 300 km length of CIPR projects were
successfully completed by HCM and Roadcare in Malaysia
COLD IN-PLACE RECYCLING
(CIPR)

RESEARCH PROGRAM
RESEARCH PROGRAM
The research program on Full Depth Reclamation (FDR) was
initiated in 2004 and completed in 2012.

Collaboration between the Public Works Department and
Kumpulan IKRAM Sdn. Bhd.

The research activities involved site construction, field test,
laboratory test and simulation test.

Four stabilizing agents namely cement, lime, emulsion and
foamed asphalt are employed in this research.
RESEARCH PROGRAM
This research aims to find out the fundamental properties of
stabilized reclaimed pavement obtained through the Full
Depth Reclamation (FDR) technique and the most cost
effective stabilization technique for reclaimed pavement.

The results from this research are used to predict the
performance of FDR pavements in Malaysia.

A guideline on the design and construction of FDR pavement
will be produced based on the results of this research.

CIPR WHERE TO USE?

Severe Crocodile Cracks
Rutting or Deformation
Pumping
MAJOR DISTRESS Structural failure
CIPR WHERE TO USE?

BLOCK CRACKING
INSUFFICIENT PAVEMENT STRUCTURE
DEEP RUTTING or DEFORMATION
SEVERE CRACKS AND POTHOLE
MATERIALS
Materials used in CIPR

Existing pavement material
Imported pavement material
(where required)
Stabilising agents

MATERIALS
Stabilising agents used in CIPR
Cement
Emulsion (QS3E)
Foamed Bitumen
Other additives
COLD IN-PLACE RECYCLING
(CIPR)

PAVEMENT EVALUATION,
DESIGN AND COST ANALYSIS
PAVEMENT EVALUATION
Data Collection / Testing
Analysis
Design
PROCESS OF
PAVEMENT
EVALUATION
Comprehensive
Analysis
D or ND Test S.C.S. Laboratory test
Analysis of Data
Identify Primary
Modes of Distress
Implementation
Economy?
Suitability?
Treatment Method
PENDOS
Output
NO
OK
PAVEMENT EVALUATION
PAVEMENT EVALUATION

-FWD
-Testpit
-Coring/DCP
-Axle load study
PAVEMENT DESIGN
Empirical Componen Analysis using
Arahan Teknik Jalan 5/85 as a guideline
Mechanistic analysis method using software
Rubicon
Mix design using samples taken from test
pit at site
COLD IN-PLACE RECYCLING
(Cement)

Proposed Design Conventional Design
40 mm ACWC
(overlay)
160 mm
ACBC
CIPR- Cement
Partial
Reconstruction
(Remove Asphalt layer)
340 mm
200mm
CIPR
(cement)
300 mm
50mm ACWC
+ 60mm ACBC
(overlay)
Sub-grade
layer
Design Comparison
COLD IN PLACE RECYCLING
(CIPR - with Cement)
Cost Analysis
* Unit Rate used in cost analysis
Asphaltic Concrete Wearing Course (ACWC20)
Asphaltic Concrete Binder Course (ACBC28)
Prime Coat
Tack Coat
Milling existing asphalt layers not exceeding 150mm
depth
Cold In-Place Recycling (CIPR) not exceeding 200mm
depth using 4% cement (CTB)
Description of Works Unit
Rate
(RM)
cu.m
cu.m
sq.m
sq.m
sq.m
sq.m
657.14
636.57
17.40
20.90
1.76
1.65
* Based on schedule of rates for road maintenance in Peninsular Malaysia
COLD IN PLACE RECYCLING
(CIPR - with Cement)
Cost Analysis
Conventional Design
(Mill and Pave)



Cost/m

(RM)

40mm ACWC (overlay)
Milling 150mm Deep

=

17.40


80mm ACBC

Prime Coat

= 1.76


80mm ACBC

ACBC 160mm

=

101.85


Tack Coat (2layers)

= 3.30


ACWC 40mm (overlay) = 26.27


Cost per sq.m = RM 150.58






Existing Road Base




Sub base





COLD IN PLACE RECYCLING
(CIPR - with Cement)


Cost/m

(RM)

50mm ACWC (overlay)

Recycle 200mm with
4 % Cement

=
20.90

60mm ACBC
Prime Coat =
1.76



ACBC 60mm

=

38.19


Tack Coat (1 layers)

= 1.65

200mm Recycle
ACWC 50mm (overlay)

=

32.85



Cost per sq.m = RM 95.35






Existing Road Base




Sub base





Proposed Design
(Cement Treated base)
(overlay)
Cost Analysis
Existing Pavement
Structure
Conventional Design
(Partial Reconstruction-
Remove Asphalt Layer)
50 mm ACWC
(overlay)
Sub-grade
layer
150 mm
ACBC
150 mm
Asphalt
Road
Base
350 mm
Cost per m
2
= RM 95.35
350 mm
200mm
CIPR
(cement)
300 mm
Proposed Design
(CIPR-Cement)
50mm ACWC
+ 60mm ACBC
(overlay)
Required overlay 135mm
Mill and replace
150 mm
COST COMPARISON
(Structural Component Analysis)
Cost per m
2
= RM 150.58
COLD IN-PLACE RECYCLING
(CIPR)

CONSTRUCTION

COLD IN-PLACE RECYCLING
(Cement)
OR
TRAIN ARRANGEMENT
COLD IN-PLACE RECYCLING
(Cement)

TYPICAL TYPE OF RECYCLER
RECYCLER WITH
TAMPING SCREED
RECYCLER WITHOUT
TAMPING SCREED
COLD IN-PLACE RECYCLING
(Cement)

TYPICAL TYPE OF RECYCLER
Direct Injection of Cement
Using WM1000 (Slurry)
At Pasir Puteh Kelantan
Manually Spread
Mechanical Spreader
COLD IN-PLACE RECYCLING
(Cement)

PLACING THE RECYCLED MATERIAL &
COMPACTION
PLACING THE RECYCLED MATERIAL
INITIAL COMPACTION
COLD IN-PLACE RECYCLING
(Cement)
TRIMMING & COMPACTION
TRIMMING (if necessary)
FINAL COMPACTION
COLD IN-PLACE RECYCLING (Lime)
COLD IN-PLACE RECYCLING
(Foamed Bitumen)

OR
TRAIN ARRANGEMENT
COLD IN-PLACE RECYCLING
(Foamed Bitumen)
COLD IN-PLACE RECYCLING
(Foamed Bitumen)
COLD IN-PLACE RECYCLING
(Emulsion)

TRAIN ARRANGEMENT
COLD IN-PLACE RECYCLING
(Emulsion)
COLD IN-PLACE RECYCLING
(CIPR)

QUALITY CONTROL

To ensure final product conforms to
specification
Test include
Measurement of relevant strength (Resilient
Modulus, ITS, UCS)
Field density test
Measurement of layer thickness
QUALITY CONTROL
Field Test
Prepare of Sample
Testing
Field Density Test in progress to
check degree of compaction
Strength of material test
Unconfined Compressive Strength Test (UCS)
QUALITY CONTROL
General Requirements for Cold Recycling
No. Parameters Test Method Requirements
1. Field
Compaction
REAM-SP 1/2005
Clause 1.5.3 Table 1.8,
BS 1377 (Sand
Replacement Method)
a)

95% for natural gravel /
crushed aggregates.
b)



97% for mixture of
crushed aggregates and
Recycled Asphalt
Pavement (RAP)
c) 98% for RAP of Job
Standard Mixture (JSM)
2. Cement
Application Rate
REAM-SP 1/2005
Clause 1.5.3 Table 1.8
10% of target rate
QUALITY CONTROL
General Requirements for Cold Recycling
No. Parameters Test Method Requirements
3. Depth of
Recycling
REAM-SP 1/2005 Clause 1.5.3
Table 1.8
10mm of target
depth
4. Thickness of
Recycled Layer
REAM-SP 1/2005 Clause 1.5.3
Table 1.8

10mm of Specified
Layer Thickness

5. Moisture
Content
REAM-SP 1/2005 Clause 1.5.3
Table 1.8, BS 1377 :Part 2

20% of the
Optimum Moister
Content determined
from AASHTO test
T180
QUALITY CONTROL
Requirements for Cement Stabilised Cold
In-Place Recycled Layer Material
Parameter Requirement
Unconfined Compression
Test (UCS), in accordance
with B.S 1881, part 116. 7-
day strength, moist curing
@ 25
o
C, height/width 1:1
Minimum 97%
of Mod.
AASHTO
density
Range (MPa)
(minimum and
maximum limits)
2 5
Indirect tensile test (ITS)
on 150mm diameter
briquette cured as for UCS
specimens, in accordance
with AASHTO T-198
Minimum 97%
of Mod.
AASHTO
density
Minimum (MPa) 0.2
Maximum cement content by weight 5%
QUALITY CONTROL
Requirements for Bitumen Emulsion Treated
Cold In-Place Recycled Layer Material
Parameter Requirement
Unconfined Compression Test (UCS), in
accordance with B.S 1881, part 116. 7-day
strength, moist curing @ 25
o
C,
height/width 1:1
Minimum 97% of
Mod. AASHTO
density
0.7
Indirect tensile test (ITS) on 100mm
diameter briquette cured at 40
o
C for 72
hours, in accordance with AASHTO T-198
Marshall
compaction (75
blows per side)

0.2
Indirect tensile test (ITS) on cured
briquettes soaked for 24 hours as above
Marshall
compaction (75
blows per side)
0.15
Minimum Tensile Strength Retained (TSR) 75%
Maximum added cement content by weight 2%
QUALITY CONTROL
Requirements for Foamed Bitumen Treated Cold
In-Place Recycled Layer Material

Parameter
Minimum
Strength
(MPa)
Unconfined Compression Test (UCS), in
accordance with B.S 1881, part 116. 7-day
strength, moist curing @ 25
o
C,
height/width 1:1
Minimum 97% of
Mod. AASHTO
density
0.7
Indirect tensile test (ITS) on 100mm
diameter briquette cured at 40
o
C for 72
hours, in accordance with AASHTO T-198
Marshall
compaction (75
blows per side)

0.2
Indirect tensile test (ITS) on cured
briquettes soaked for 24 hours as above
Marshall
compaction (75
blows per side)
0.15
Minimum Tensile Strength Retained (TSR) 75%
Maximum added cement content by weight 2%
COLD IN-PLACE RECYCLING
(CIPR)
Advantages
1. Faster and more efficient as minimal excavation and dump
trucks required;
2. Reused of existing materials and reduces new construction
materials and transport cost;
3. The technique can give equivalent pavement structure
condition and cost saving compare with conventional method;
4. Increases the shear strength and reduces the moisture
susceptibility of granular materials;
5. Flexible and fatigue resistant (Foamed Bitumen and
Emulsion);
6. Cost savings with approximately 25% - 55%.
Advantages
7. Consistent Mixing
8. Precise control of layer thickness.
9. Less reliance on fine weather conditions.
10. Greatly reduced traffic disruption and improved safety
COLD IN-PLACE RECYCLING
(CIPR)
COLD IN PLACE RECYCLING
(CIPR)
Disadvantages
1. Doesnt solve problems with base course or subgrade
2. Material and construction variation is greater than for
conventional rehabilitation techniques.
3. The CIPR mixture need to be cured for a period of time in
order to gain strength.
4. Difficulty of controlling the density during works.
Before Construction During Construction
After Construction
COLD IN PLACE RECYCLING PROCESS
COLD IN PLACE RECYCLING IN PROGRESS
THANK YOU